How To Conduct Material Condition Inspections

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How to Conduct
Material Condition Inspections
TR-104514
September, 1994
Prepared by
Ernie Hayden
Electric Power Research Institute
Prepared for
Nuclear Maintenance Applications Center
1300 Harris Boulevard
Charlotte, North Carolina 28262
Operated by
Electric Power Research Institute
3412 Hillview Avenue
Palo Alto, California 94304
EPRI Project Manager

Ernie Hayden
Nuclear Power Division
NMAC products and
services are geared
directly to day-to-day
maintenance activities,
and have proven both
extremely successful and
cost-effective in improving
maintenance practices.
NMAC provides a conduit

for the ongoing exchange
of information among
utilities and industry
maintenance personnel.
The NMAC approach

helps individual nuclear
facilities incorporate the
collective wisdom of the
industry into their own
maintenance and
operating plans.
operated by EPRI
EPRI Licensed Material
NMAC Tech Notes
Preface
This Tech Note focuses primarily identify those areas that can be
on the mechanics of performing improved.
power plant or industrial facility
Information provided in this Tech
material condition inspections.
Note is not intended to be a
The information provided can be
discussion on how inspections can
used as a tool to teach the
be used as management tools nor
non-licensed operator, field/system
how management should trend the
engineer, manager, supervisor or
results. Also, methods for tagging
craftsman how to enter the power
or otherwise identifying currently
block and look for material
existing deficiencies are not
condition problems and to readily
addressed in this Tech Note.
Table of Contents
1.0 Introduction 3
2.0 Basic Tools 5
3.0 Data Collection 7
4.0 Tour Planning 11
5.0 “Working A Room” 15
6.0 Conclusion 16
Appendix A - Plant Deficiencies 17
Appendix B - References 23
How to Conduct Material Condition Inspections 1

NMAC Tech Notes
1.0 Introduction
Material condition inspections are frequently performed at every industrial

facility. The inspection can be formal or informal and performed by outside
agencies, managers, supervisors, operators, or craftsmen. These inspections
and how well they are performed are usually reflected in the overall condition
of the plant and the frequency of “surprise” failures. Therefore, by walking
down the plant, you need to focus on looking for problems and maintaining
an attention to the details. Otherwise, you will normally not find the
problems-except for the 5-gallon per minute leak and the 8-foot steam
plume. Therefore, one of the first and foremost requirements for a thorough
material condition inspection is to ensure that the inspector has a
“questioning attitude” and is looking for problems down to the smallest detail.
What is a material condition inspection? Basically, a material condition

inspection is a focused, critical, and careful examination of an industrial
component, system, or structure. The intent of the inspection is to locate and
identify problems such as leaks, lubrication problems, missing handwheels,
clogged filters, broken gauges, loose fasteners, housekeeping deficiencies, and
missing lights. The inspections can be formally scheduled and performed or
they can be spontaneously executed.
The key elements or features of a material condition inspection include the

following:
the “right” tools
a plan of attack
a method of recording the deficiencies
a systematic technique
the “right attitude”
This Tech Note will review these key elements and how they can be applied
during an inspection. Frequent, quality material condition inspections will
help ensure that small problems are identified and that they will not expand
into larger problems resulting in industrial safety hazards or costly plant
shutdowns.

NMAC Tech Notes
2.0 Basic Tools
Thorough performance of the inspection requires that the inspector has the
right set of basic tools. These tools include:
flashlight
rag (or similar wiping cloth/paper)
pen knife
inspection mirror(s)
personal protective clothing and equipment
method of recording deficiencies, problems, and notes

(covered in Section 3.0)
Specifics on these tools are detailed in the following sections.
2.1 Flashlight
The right flashlight used by the inspector can make a difference when
performing the inspection. Basically, the optimal flashlight is one that can
be turned on and off with a single hand (some flashlights require two-hand
operation by rotating the head of the flashlight—very inconvenient!) and can
be carried in a hip or shirt pocket. The flashlight should have a krypton bulb
for high candle power and fresh batteries installed before beginning the tour.
2.2 Rag or Similar Wiping Material
Occasionally during the inspection, it may be necessary to wipe off dirt,

grease, oil, or water in order to read a name plate or label, or to generally get
a closer view of the component in question. Therefore, a cloth rag or heavy
duty paper wipe is very helpful and can be easily carried in a pocket.
Caution: Do not use a rag or wipe in a radiologically, chemically,

or biologically hazardous environment. In these cases, it is best to
not touch the component to prevent personal injury or spread of
contamination.
2.3 Pen Knife
A pen knife or small metal “scratch and poke” tool (e.g., dental tool) is helpful
during inspections. This tool should be small enough to carry in a pocket yet

NMAC Tech Notes
sturdy enough to examine scale or rust build up and scratch through

caked-up dirt. Again, similar to the caution above for rags, do not use
your knife to rub or scratch in a radiologically, chemically, or
biologically hazardous environment.
Caution: Do not use a conductive knife or mirror around energized

electrical equipment.
2.4 Inspection Mirrors
Occasionally, based on where the inspection will be performed and whether

or not ready access to 360° views of the component is available, a small,
pocket-sized inspection mirror may be handy. This tool may be most
appropriate when examining valve stems, valve packing, items immediately
against a wall or barrier, etc. In general, use of a mirror is mainly a personal
option.
2.5 PersonaI Protective Clothing
When you prepare for your inspection, prepare to get dirty and to be “in the
plant.” Therefore, equipment such as a hard hat, safety glasses and hearing
protection are appropriate. Also, a set of coveralls is very useful because of
the cleanliness factor as well as the number of available pockets for the tools
identified above.
6 How to Conduct Material Condition Inspections

NMAC Tech Notes
30
■ Data Collection
The purpose of the inspection, of course, is to identify and record the

problems in the plant for repair. However, depending upon the detail and
size of the inspection, you need to record the problems identified. There are
two predominant methods used in this area which include voice recording
and written notes.
3.1 Hand-held Audio Recorder
A small hand-held, battery-operated cassette recorder has been frequently

used during inspections. The inspector can make verbal notes regarding the
deficiencies. Later, the recorded notes can be transcribed to written form via
work order/work request forms or inspection reports.
Benefits:
This technique allows the inspector to work faster and make more
detailed observations rather than writing down all details.
Limitations:
The recording needs to be transcribed which delays the transfer of

deficiencies to the plant’s work control system.
The inspector is not “prompted” to remember to include all pertinent

details such as component identifier, location, etc. Therefore, the
narrative may not be complete in order to specifically identify the
deficiency.
3.2 3x5 Card Technique
This technique involves the inspector carrying a collection of preprinted 3x5

inch cards (see Figure 1) to conduct the inspection. These cards help prompt
the inspector to ensure the appropriate details regarding the deficiency are
collected thus ensuring the deficiency will be correctly located and corrected.
General guidelines for using these cards are as follows:
Quantify the problem (e.g., 15 drops per minute leak, 7 of 10 bolts

missing, etc.).
Fill in the required data to ensure the deficiency can be readily identified.
Don’t skimp on information . . . . . . ..the more the better.

NMAC Tech Notes
Figure 1 - 3 x 5 Card
Benefits:
The inspector is “prompted” to ensure complete data is collected on the

deficiency.
The cards are easy to carry/use and can be sorted for common problems,
etc.
Information can be easily transferred to work orders for later correction.
Limitations:
It may be difficult to release the cards from a radiologically hazardous

area due to potential contamination.
The cards need to be completed by hand and be legible in an environment

not conducive to good penmanship.
3.3 Work Order Completion Technique
This particular method of documenting the deficiencies is the quickest way to

identify a problem directly into the work control system. Specifically, the
inspector carries a stack of work order forms with him into the plant and
completes the forms in the field. This approach is efficient in completing the
work order forms and the component information/tag, etc. is readily available
to “fill in the blanks”; however, this system significantly slows down the
inspection, and the legibility of completing the form is in jeopardy.

NMAC Tech Notes
Benefits:
Work order forms are completed in the field thus minimizing incomplete
entries.
Limitations:
Inspection performance is significantly slowed.
Legibility of the work order forms is in jeopardy due to in-field completion.
It may be difficult to release the completed forms filled out in a

radiologically contaminated area.
3.4 Notepad Technique
This approach is the oldest and simplest format for collecting data during the
inspection. The primary approach to this technique is to jot down the
deficiencies in a pocket notebook, spiral bound notebook, steno pad, etc.
Overall, the information is collected; however, this process could result in
inadequate details on the problems. On the other hand, taking detailed notes
in this way is better than no notes at all.
Benefits:
The notepads are easy to use and no special “forms” are required for the
process to work.
Limitations:
The inspector is not “prompted” to ensure complete data is collected on

the deficiency.
It may be difficult to release the notepads from a radiologically hazardous

area due to potential contamination.
The notes are completed by hand and may be illegible.

NMAC Tech Notes
4.0 Tour Planning
As in most activities, proper planning will lead to improved performance.

Therefore, it is in the inspector’s best interest to plan the inspection including
the tour route and the focus of the inspection. The tour itself can include the
following approaches:
“random” inspection
focused area or room inspection
material condition feature inspection (e.g., just look at bolts)
inventory and validation of currently identified deficiencies
Each tour approach identified is discussed below. Also, the next section will
discuss the ways to “work a room” during the inspections.
Before beginning an inspection, some preparatory steps may be appropriate.

These steps could include the following:
Review drawings of the areas to be inspected.
Verify access to the areas (e.g., keys, permits, approvals, etc.).
Check that all tools, pens, paper, forms, etc. are available and ready.
Inform the shift supervisor of your inspection tour if appropriate or

necessary.
Once these steps are performed, you are ready to continue.
4.1 Random Approach

This inspection approach, also called inspection by “walking around,” is
performed in the manner denoted. In other words, the inspector conducts the
inspection with minimal pre-planning. The inspection is conducted at the
whim of the inspector with no predetermined focus on buildings, components,
systems, etc. The inspector primarily enters the plant with pen in hand and
begins to itemize the deficiencies. This approach does result in identified
deficiencies; however, the inspector may not be using his time effectively due
to the random approach into the plant. Also, this approach would tend to
direct the inspection to those areas of “easy access,” hence, the harder to view
locations would be missed.
In general, this approach is not recommended.

NMAC Tech Notes
4.2 Focused Area Inspection
The focused area inspection is a commonly used approach in the military.

This technique is commonly referred to as a “zone inspection.” At a power
plant, this approach would include assigning the inspector to a room, area of
the plant, or specific building for the inspection.
A prerequisite to performing this inspection technique is to divide the power

plant into a collection of “inspection zones.” These zones could be specific
rooms, separate elevations of larger buildings (e.g., basement of the turbine
building), or specific areas of the outside yard. The zones should be small
enough to accommodate a thorough inspection in about two to four hours;
however, they should not be so small such that the plant is segmented into
an excessive number of zones.
Once these zones are defined, inspections are then performed in the separate
zones on a rotating basis. Therefore, the entire plant/facility is inspected on
a periodic basis assuming the inspections of the zones are performed at a
defined interval (e.g., weekly basis).
4.3 Focused Material Condition Element
In order to make the inspections more efficient and to accommodate a more

detailed review, some inspections should be focused on a material condition
element.
An example of this technique would be for the inspector to conduct an

inspection of bolting and thread engagement in the plant or plant zone
assigned. Before the inspector begins his inspection, he could study
appropriate plant procedures and EPRI NP-5067, Good Bolting Practices - A
Reference Manual for Nuclear Power Plant Maintenance Personnel (Volume 1:
Large Bolt Manual). This review would give the inspector necessary
inspection “criteria” for the inspection as well as add to his professional and
technical knowledge. Later, as the focused inspection is performed, trends in
bolting installation may be revealed that would otherwise be missed if a
“random” or “general” inspection were performed.
Other focused inspections could include inspections for lubrication practices,

valve packing, electrical connections, ground straps, lighting, preservation,
labels, housekeeping, industrial safety, radiological protection, temporary
modifications, chemical control, etc.

NMAC Tech Notes
Many EPRI/NMAC references that can be used in preparation for focused

element material condition inspections are included in Appendix B.
4.4 Inventory/Validation of Currently Existing Deficiencies in Work Control

System
This final technique for the inspection is a method to validate those

deficiencies currently listed in the work control system. Basically this
inspection involves comparing a printout of active deficiencies in the work
control system (if available) to the actual deficiencies as they exist in the
field. The inspector can perform this comparison by system, zone, room, or
building. Also, this inspection can be performed strictly by “checking off’
those items that are still valid and canceling those problems that no longer
exist or have been repaired and not removed from the work control system.
Another technique that has been proven effective when validating currently
existing deficiencies is the use of a two-way radio. In this approach, the field
inspector identifies a deficiency in his inspection zone/system, etc. He radios
in the deficiency, component identification, etc. to an individual at a
computer terminal with access to the work control system. The work control
verifier then calls up the component, validates the deficiency, or notes that it
is not in the system for later follow-up. This technique is very efficient. A
secondary benefit allows for the plant to ascertain radio coverage and “blind
spots” as the inspector roams his assigned inspection area.
Disadvantages of this technique include:
A minimum of two persons is required for inspection.
If the inspector finds himself in a “blind spot”, he has to exit the room to
report.
The message can be “garbled” due to interferences.
Caution: Plant management should be cautioned that keying radio

transmitters near some installed instrumentation has led to
activation of plant components. Therefore, if this inspection
technique is selected caution should be exercised

NMAC Tech Notes
5.0 “Working A Room”
Regardless of the type of inspection chosen-even on random plant

tours–there are several key points considered generic to all inspections. The
key consideration overall is to always have a questioning attitude.
Continually look for problems, deficiencies, and those items that may not be a
“deficiency” per se but could be improved upon. A detailed list of many types
of problems to look for during the tours is included in Appendix A.
Other general approaches to all inspections include the following:
5.1 Surveying the Area
Whenever you approach an area to be inspected, the natural tendency is to

inspect the well-traveled areas and to inspect those areas at eye-level.
Unfortunately, the normal pathways tend to remain relatively deficiency-free
due to frequent traffic and other reasons. Therefore, the inspector needs to
make it a point to look in areas that are not normally observed,
out-of-the-way, and considered “limited access. ”
One approach to “working” an area or room is to conduct a “perimeter” tour.

This method has the inspector walking around the room/zone by remaining
close to the outside wall of the room. This path would tend to lead the
inspector to viewing areas behind equipment, panels, etc. Also, most
pathways through a room are in the center of the room, hence, you can focus
your inspection on areas infrequently viewed. You may need a Radiological
Work Permit (RWP) for climbing above certain heights.
Other considerations to include in your inspection are to look up, look down,
and look under. Again, a systematic inspection approach that helps in this
area is to perform a top down spiral inspection. In other words, begin at the
top of the room and inspect the room in a downward spiral. Hence, you will
have inspected almost the entire room. Also, it is a natural tendency to not
look up during an inspection, therefore this technique guides the inspector to
view the “less observed” areas.
5.2 Don’t Operate/Don’t Touch Rule
As a general rule for the inspection, it is best if the inspector avoids operating
equipment, opening panels, and handling components or equipment. This is
especially critical in order to avoid spurious instrumentation trips caused by
cabinet door closures, or other “shocks.” If the inspector is interested in
looking inside cabinets and enclosures, the inspector should first get

NMAC Tech Notes
permission from the shift supervisor. It would also be better if the roving
operator or a qualified craftsman open the cabinets rather than the inspector.
An additional reason to avoid touching equipment–especially in an industrial

facility–is to avoid personal contamination or injury from radiological or
chemical residue. Even with protective clothing, it is typically unnecessary
to touch the equipment to still perform an adequate inspection.
5.3 Attention to Detail
Although this may seem repetitive, the secret to a successful inspection is to

maintain a questioning attitude and focus on the details. For instance, when
inspecting a pump, you need to look at the entire pump and prime mover with
an eye for the details. The inspector needs to ask questions such as:
Are the foundation bolts installed correctly?
Is the oiler full?
Does the pump “sound” right?
Is it clean?
Is there evidence of new or even old leaks?
Is the foundation drain plugged or clear?
Is the machine labeled correctly and completely?
Are there any missing fasteners, handwheels, parts?
Is the instrumentation tubing crimped?
Is there evidence of unusual vibration?
Are there any signs of corrosion?
What is the condition of paint/coatings?
Are all safety devices properly installed?
6.0 Conclusion
An eye for the details and a questioning attitude will lead to a more thorough
inspection. Also, with practical techniques the inspections will result in a
better assessment of the plant’s overall condition and, with appropriate
corrective action, will ensure that the plant equipment is reliable.

NMAC Tech Notes
APPENDIX A - Plant Deficiencies - Examples
MATERIAL CONDITION DEFICIENCIES
Leaks - water, steam, oil, air Gauges/Instruments (including

packing condition control room)
valve stem not in calibration (calibration
mechanical seals sticker missing or outdated)
flanges inoperable
body to bonnet internal leak by face broken
evidence of temporary leak pointer missing
repairs pointer bent
use of blotter and oil dry excessive oscillation
use of absorbent “pigs”
Drains/drain holes
leakage from pipe fittings
clogged
Valve/Pump Packing full
bottomed out adjustment p l ugged
dirty screens or grating missing
rusted glands
Lines/pipes
Lubrication - oil, grease loose
too much unbracketed
too little unsupported
sight glasses bent
bull’s eyes insulation missing or damaged
flow indicators
Fasteners
dip sticks
loose
grease cups
missing
grease (zirc) fittings
stripped
Handwheels/operators not adequately engaged
missing
Indicating Lamps
key or pin missing
missing
identification label missing
burned out
broken
missing covers
Filters/screens/louvers flickering
clogged
Panels
dirty
covers missing
missing
open
loose
dirt and debris inside

NMAC Tech Notes
Area Lighting Preservation

burned out rust
bulbs missing corrosion
flickering missing or damaged
inadequate insulation/lagging
Cables/Leads/Wires Labels
unsecured missing
worn or frayed insulation unclear
improper terminations inaccurate
broken/damaged
Motors/Generators
dirty
brush rigging pigtails broken
ground straps loose/missing
excessive noise/vibration
running hot
TEMPORARY PLANT SYSTEM MODIFICATIONS

hoses connected to two or more fluid systems (even if valved out)
plugged or taped floor drains
temporary skid-mounted equipment connected to plant systems
temporary electrical feeder cables or panels
permanent equipment that is electrically or mechanically disconnected
temporary shielding (lead blankets, sheets, or stacks of bricks)
temporary tank level indicators
disabled annunciators
electrical jumpers not part of system/component design
lifted leads/unterminated electrical cables
material substitutions (mismatched bolts, pipe material, etc. )
temporary leak repairs
temporary test equipment
temporary ducting or other HVAC alterations

NMAC Tech Notes
RADIOLOGICAL PROTECTION DEFICIENCIES
Postings
signs illegible
signs inappropriate
Barriers
not clearly positioned
not appropriate to preclude uncontrolled access
Equipment or instruments
overdue for calibration
damaged
Radioactive material
unidentified
uncontrolled
unwrapped
Protective clothing containers

overflowing
difficult to access when departing from posted area
non-radioactive material in radwaste containers
Storage
accumulation of radioactive materials, tools, drums in other than
designated areas
Spills/leaks
not contained
not redirected to prevent spread of contamination
SEISMIC DEFICIENCIES
Unrestrained items that could damage vital equipment during a seismic

event
ladders
toolboxes
scaffolding
removed equipment
test equipment
hoists

NMAC Tech Notes
INDUSTRIAL SAFETY DEFICIENCIES
Ladders
no safety chain barrier across access
ladder rungs broken
lighting less than adequate
not properly secured
Scaffolding/catwalks
no safety rails installed
toe guards missing (if above 10 feet)
improperly installed or secured
disrepair
Compressed gas bottles

unsecured
caps missing
unlabeled
leaking
Tripping/slipping/bumping hazards
temporary hoses
piping
holes in floor
oil/water on floor
Spills/leaks
not contained
not redirected to prevent spread of contamination
not labeled or taped with black/yellow hazard tape
protrusions in aisleways without protection devices/warnings
Maintenance Shop Equipment

guards not installed
safety signs missing/damaged
work space not marked off around each piece of equipment
Fire hazards
untreated wood in power block
packaging, boxes, paper, flammables in excess of fire loading
flammable liquids in unauthorized containers
Fire Protection Equipment

hoses improperly racked
inspections not up to date
fire extinguishers not in place/labeled
emergency cabinets not adequately stocked, not controlled
access to safety equipment not clear

NMAC Tech Notes
Posting and control of hazardous or confined areas

zones not clearly defined
permits not posted
warning signs not posted
safety watches not posted outside of occupied confined spaces
Eyewash stations/showers
access is restricted
not located near hazard
not well maintained or tested
not adequately charged (for charged bottle types)
CHEMICAL CONTROL DEFICIENCIES
Chemicals
expendable chemicals left opened or loose in the plant
incompatible chemicals stored together
storage areas not equipped with appropriate safety equipment such as
eye wash stations, safety showers, and fire protection equipment
containers corroded or leaking
Bulk chemicals
missing identification, safety precautions, first aid labeling
not stored in designated storage facilities/areas
stored outside, unprotected from weather and sunlight
HOUSEKEEPING DEFICIENCIES
trash accumulated behind panels and under equipment

cluttered areas
dirt accumulation
trash accumulated in cable trays
undisposed packing material
cigarette stubs
overflowing trash containers
tool cribs in disarray
tools or parts lying around
caked dirt and debris on equipment and bedplates
signs and labeling in disarray
storage areas disorderly
shop areas cluttered

NMAC Tech Notes
APPENDIX B - References*
DIESEL GENERATORS
EPRI NP-6314 R1 Storage/Handling of Fuel Oil for Standby Diesel
Generator Systems (Rev. 1)
ELECTRICAL - BATTERIES
EPRI TR-1OO249 Emergency Battery Lighting Unit Maintenance
Guide
EPRI TR-1OO248 Stationary Battery Maintenance Guide
EPRI EL-5036, V9 DC Distribution System
ELECTRICAL - CABLES
EPRI NP-7485 Power Plant Practices to Assure Cable Operability
EPRI EL-5036, V4 Wire and Cable
ELECTRICAL - CIRCUIT BREAKERS
EPRI EL-5036, V7 Auxiliary Electrical Equipment
EPRI NP-741O-V1-P1 Circuit Breaker Guide - Vol. 1/ Low Voltage, ABB
EPRI NP-741O-V1-P2 Circuit Breaker Guide - Vol. 1/ Low Voltage, GE

EPRI NP-741O-V1-P3 Circuit Breaker Guide - Vol. 1/ Low Voltage,
Westinghouse - DB
EPRI NP-741O-V1-P4 Circuit Breaker Guide - Vol. 1/ Low Voltage,
Westinghouse - DS
EPRI NP-741O-V2-P1 Circuit Breaker Guide - Vol. 2/ Medium Voltage,
ABB
EPRI NP-741O-V2-P2 Circuit Breaker Guide - Vol. 2/ Medium Voltage,
GE
EPRI NP-741O-V2-P3 Circuit Breaker Guide - Vol. 2/Medium Voltage,
Westinghouse
EPRI NP-741O-V3 Molded Case Circuit Breaker
ELECTRICAL - FREEZE PROTECTION
EPRI EL-5036, V12 Electric Freeze Protection and Process Heating
ELECTRICAL - GROUNDING AND LIGHTNING PROTECTION
EPRI EL-5036, V5 Grounding and Lightning Protection
ELECTRICAL - MOTORS
EPRI NP-6407 Guidelines for the Repair of Nuclear Power Plant
Safety-Related Motors (NCIG-12)

NMAC Tech Notes
EPRI NP-7502 Electric Motor Predictive and Preventive

Maintenance Guide
EPRI EL-5036, V6 Motors
ELECTRICAL - RELAYS
EPRI NP-7216 Protective Relay Maintenance and
Application Guide
EPRI TR-102067 Maintenance and Application Guide for Control
Relays and Timers
EPRI EL-5036, V8 Station Protection
ELECTRICAL - TRANSFORMERS
EPRI EL-5036, V2 Power Transformers
FASTENERS
EPRI NP-5067 V1 Good Bolting Practices - Large Bolts
EPRI NP-5067 V2 Good Bolting Practices - Small Fasteners
EPRI NP-5067 WC Good Bolting Practices - Small Fasteners Matrix
Wall Charts (2)
EPRI NP-6316 Guide for Threaded Fasteners
Good Bolting Practices - Pressure Boundary
Bolting Problems Video
INSTRUMENT AIR
EPRI NP-7079 Instrument Air System Guide
INSTRUMENTATION AND CONTROLS
EPRI TR-1OO856 Instrumentation and Control Maintenance
Experience Reference
EPRI EL-5036, V10 Electrical Control and Instrumentation
LUBRICATION
EPRI NP-4916 R1 Lubrication Guide (Revision 1)
EPRI CS-4555 Guidelines for Maintaining Steam Turbine
Lubrication Systems
MATERIAL CONDITION INSPECTIONS (General)
EPRI TR-101108 Boric Acid Corrosion Evaluation, Phase I
PIPING
EPRI NP-6384D Freeze Sealing (Plugging) of Piping Guide

NMAC Tech Notes
PUMPS
EPRI NP-7413 Deep Draft Vertical Centrifugal Pump Maintenance
and Application Guide
TEMPORARY REPAIRS
EPRI NP-6523D On-Line Leak Sealing Guide
TERRY TURBINES
EPRI NP-6909 Terry Turbine Controls Guide
VALVES AND VALVE OPERATORS
EPRI NP-7412 Air Operated Valve Maintenance Guide
EPRI NP-7212 Anchor Darling - Main Feed Isolation Guide
EPRI NP-7211 Anchor Darling - Main Steam Isolation Guide
EPRI NP-5479 Application Guide for Check Valves
EPRI NP-7501 Application Guide for Motor Operated Butterfly Valves
EPRI NP-6660D Application Guide for Motor Operated Valves

EPRI NP-7414 Solenoid Valve Maintenance and Application Guide
EPRI NP-7124 Technical Repair Guide for Limitorque Valve Operators
Model SMB-0-4
EPRI NP-6631D Technical Repair Guide for Limitorque Valve
Operators Model SMB-00
EPRI NP-6229D Technical Repair Guide for Limitorque Valve
Operators Model SMB-000
WELDS
EPRI NP-5380, V1-3 Visual Weld Acceptance Criteria
*These documents are subject to revision.

In the face of a continuing attention to
operations and maintenance costs at nu-
clear power plants, the future of the
industry depends largely upon increas-
ing plant availability and improving op-
erating efficiency. The success in
achieving these objectives is dependent
upon the success of each plant’s equip-
ment maintenance program.
NMAC’S goal
The goal of the Nuclear Maintenance

Applications Center (NMAC), operated
by EPRI, is to provide member utilities
with practical, proven maintenance
practices and expertise which will assist
power plant personnel in effectively
managing their planned and emergent
maintenance requirements; and, to fa-
cilitate the transfer of maintenance-re-
lated technology at a working level
within the nuclear power industry.
ABOUT EPRI
The mission of the Electric Power Research Institute is to discover, develop, and deliver advances in
science and technology for the benefit of member utilities, their customers and society.
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How To Conduct Material Condition Inspections

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SINGLE USER LICENSE AGREEMENT

THIS IS A LEGALLY BINDING AGREEMENT BETWEEN YOU AND THE

EPRI Project Manager

NMAC provides a conduit

The NMAC approach

How to Conduct Material Condition Inspections 1

Material condition inspections are frequently performed at every industrial

What is a material condition inspection? Basically, a material condition

The key elements or features of a material condition inspection include the

the “right” tools

a method of recording the deficiencies

the “right attitude”

How to Conduct Material Condition Inspections 3

2.0 Basic Tools

rag (or similar wiping cloth/paper)

personal protective clothing and equipment

method of recording deficiencies, problems, and notes

Specifics on these tools are detailed in the following sections.

2.2 Rag or Similar Wiping Material

Occasionally during the inspection, it may be necessary to wipe off dirt,

Caution: Do not use a rag or wipe in a radiologically, chemically,

2.3 Pen Knife

How to Conduct Material Condition Inspections 5

sturdy enough to examine scale or rust build up and scratch through

Caution: Do not use a conductive knife or mirror around energized

2.4 Inspection Mirrors

Occasionally, based on where the inspection will be performed and whether

2.5 PersonaI Protective Clothing

6 How to Conduct Material Condition Inspections

The purpose of the inspection, of course, is to identify and record the

3.1 Hand-held Audio Recorder

A small hand-held, battery-operated cassette recorder has been frequently

The recording needs to be transcribed which delays the transfer of

The inspector is not “prompted” to remember to include all pertinent

3.2 3x5 Card Technique

This technique involves the inspector carrying a collection of preprinted 3x5

General guidelines for using these cards are as follows:

Quantify the problem (e.g., 15 drops per minute leak, 7 of 10 bolts

Don’t skimp on information . . . . . . ..the more the better.

How to Conduct Material Condition Inspections 7

The inspector is “prompted” to ensure complete data is collected on the

Information can be easily transferred to work orders for later correction.

It may be difficult to release the cards from a radiologically hazardous

The cards need to be completed by hand and be legible in an environment

3.3 Work Order Completion Technique

This particular method of documenting the deficiencies is the quickest way to

8 How to Conduct Material Condition Inspections

Inspection performance is significantly slowed.

Legibility of the work order forms is in jeopardy due to in-field completion.

It may be difficult to release the completed forms filled out in a

3.4 Notepad Technique

The inspector is not “prompted” to ensure complete data is collected on

It may be difficult to release the notepads from a radiologically hazardous

The notes are completed by hand and may be illegible.

How to Conduct Material Condition Inspections 9

4.0 Tour Planning

As in most activities, proper planning will lead to improved performance.

focused area or room inspection